Egg carton with lugless denest-feature and related methods

ABSTRACT

An egg carton may include a lid having first and second opposing longitudinal sides, first and second opposing ends, a major surface, and first and second denest-features respectively near the first and second opposing ends. Each denest-feature may have an upper wall extending from the major surface, an outward flange being parallel to the major surface, and a curved surface extending from the upper wall to the outward flange. The egg carton may include a base having first and second opposing longitudinal sides, first and second opposing ends, and lower egg receptacles for receiving corresponding eggs, and a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.

TECHNICAL FIELD

The present disclosure relates to the field of food packaging, and, more particularly, to egg cartons and related methods.

BACKGROUND

Food packaging is a major component of the U.S. food industry. Indeed, the just-in-time delivery system of major supermarkets throughout the U.S. necessitates that food be quickly and safely transported to the local supermarket from production centers and distribution centers. Because of this, food packing is a major industry, in and of itself, in the U.S.

Food packaging has several functional purposes: product protection, product safety, product freshness, and brand marking. The product protection feature is particularly important for fragile food products, such as eggs. Eggs are typically shipped in egg cartons, which can carry anywhere from 6-48 eggs therein.

In fact, there have been several approaches to the egg carton. For example, U.S. Pat. No. 9,169,058 to Ramirez et al. discloses an egg carton comprising a lid, a cover, and a base of a tri-fold egg carton. U.S. Patent Application Publication No. 2010/0187150 to Dijkstra et al. discloses another egg carton. This egg carton is made of molded pulp, and includes a bottom part including compartments matching at least partially the outer contours of the articles contained within the unit, and a cover part. The cover part includes a top surface and substantially planar front and rear surfaces and substantially planar end surfaces.

Another aspect to egg cartons is transportation and storage of unused egg cartons at the egg production facility. Typically, during storage, large numbers of egg cartons are stacked in a nested arrangement. Given that large numbers of egg cartons are needed at egg production facilities, it is helpful that the unused egg cartons take up as little space as possible, and are readily denested.

SUMMARY

Generally, an egg carton may include a lid comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and first and second denest-features respectively adjacent the first and second opposing ends. Each denest-feature may include an upper wall extending from the major surface, an outward flange being substantially parallel to the major surface, and a curved surface extending from the upper wall to the outward flange. The egg carton may also include a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs. The egg carton may also comprise a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.

In some embodiments, the base may comprise a plurality of posts between the plurality of lower egg receptacles. The plurality of posts may include first posts and second posts, the second posts having a height less than that of the first posts. Adjacent first posts may include a respective second post therebetween.

Moreover, the major surface of the lid may be flat. The upper wall may extend vertically along opposing sides of the curved surface. For example, the upper wall may be canted at an angle of 6-10 degrees from an axis perpendicular to the major surface of the lid.

Also, each denest-feature may be lugless. Each lower egg receptacle may have first and second pairs of opposing curved protrusions. Each lower egg receptacle may comprise a bottom surface between the first and second pairs of opposing curved protrusions and comprising a dimple for receiving a respective egg.

Another aspect is directed to a method of making an egg carton comprising forming a lid. The lid may include first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and first and second denest-features respectively adjacent the first and second opposing ends. Each denest-feature may have an upper wall extending from the major surface, an outward flange being substantially parallel to the major surface, and a curved surface extending from the upper wall to the outward flange. The method may include forming a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs. The method may also comprise forming a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.

Yet another aspect is directed to a method of packaging a plurality of eggs in an egg carton. The method may include positioning the plurality of eggs in the egg carton. The egg carton may include a lid comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and first and second denest-features respectively adjacent the first and second opposing ends. Each denest-feature may include an upper wall extending from the major surface, an outward flange being substantially parallel to the major surface, and a curved surface extending from the upper wall to the outward flange. The egg carton may also include a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs. The egg carton may also comprise a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of an egg carton, according to the present disclosure.

FIG. 2 is a schematic top plan view of the egg carton of FIG. 1.

FIG. 3 is a schematic bottom plan view of the egg carton of FIG. 1.

FIG. 4 is a schematic front plan view of the egg carton of FIG. 1.

FIG. 5 is a schematic right side plan view of the egg carton of FIG. 1.

FIG. 6 is a schematic left side plan view of the egg carton of FIG. 1.

FIGS. 7A and 7B are schematic perspective views of portions of the egg carton of FIG. 1.

FIG. 7C is a schematic top plan view of a portion of the egg carton of FIG. 1.

FIGS. 8A and 8B are perspective views, respectively, of a nested stack of egg cartons of FIG. 1, and a nested stack of egg cartons, according to the prior art.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which several embodiments of the invention are shown. This present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Like numbers refer to like elements throughout.

Referring to FIGS. 1-7C, an egg carton 10 according to the present disclosure is now described. The egg carton 10 illustratively includes a lid 11. The lid illustratively includes a first opposing longitudinal side 12, a second opposing longitudinal side 13, a first opposing end 14, and a second opposing end 15. The first opposing end 14 and the second opposing end 15 are between the first opposing longitudinal side 12 and the second opposing longitudinal side 13.

The lid 11 illustratively includes a major surface 16 extending between the first opposing longitudinal side 12 and the second opposing longitudinal side 13 and between the first opposing end 14 and the second opposing end 15. Moreover, the major surface 16 of the lid 11 may be substantially flat (i.e. there is no structure (e.g. window, down posts, etc.) or other protrusions that would touch the cell section (base) of the carton, other than the lid).

The lid 11 illustratively includes a first denest-feature 17 and a second denest-feature 20 respectively adjacent the first opposing end 14 and the second opposing end 15. The egg carton 10 illustratively includes a base 21. The base 21 illustratively includes a first opposing longitudinal side 22, and a second opposing longitudinal side 23. The base 21 illustratively includes a first opposing end 24 and a second opposing end 25 being between the first opposing longitudinal side 22 and the second opposing longitudinal side 23. The base 21 illustratively includes a plurality of lower egg receptacles 19 a-191 for receiving a corresponding plurality of eggs (not shown). In the illustrated embodiment, the egg carton 10 includes twelve lower egg receptacles, but it should be appreciated that this is only an exemplary embodiment. In other words, other embodiments of the egg carton 10 may comprise more or less egg receptacles (e.g. 6, 24, 26, 48).

The egg carton 10 illustratively includes a hinge strip 26 coupled between the lid 11 and the base 21 and configured to permit the lid to fold between a closed position and an open position. As will be appreciated, the egg carton 10 is illustratively depicted in the open position, and the lid 11 may be closed onto the base 21 with an interface locking arrangement discussed herein.

As perhaps best seen in FIGS. 1 & 4, the base 21 illustratively includes a plurality of posts 27 a-28 c between the plurality of lower egg receptacles 19 a-191. In particular, the plurality of lower egg receptacles 19 a-191 is arranged in two adjacent and aligned rows, and the plurality of posts 27 a-28 c are positioned between the two rows. The plurality of posts 27 a-28 c illustratively includes first posts 27 a-27 b and second posts 28 a-28 c. The second posts 28 a-28 c have a height less than that of the first posts 27 a-27 b. Moreover, adjacent first posts 27 a-27 b include a respective second post 28 a-28 c therebetween.

In other words, the first posts 27 a-27 b are spaced apart in arrangement. Also, when the egg carton 10 is in the closed position, the major surface 16 of the lid 11 will rest on the uppermost portions of the first posts 27 a-27 b, thereby providing crush protection from the top side. Advantageously, the reduced height of the second posts 28 a-28 c reduces the amount of material for manufacture without sacrificing egg protection.

As perhaps best seen in FIGS. 1 & 3, the first posts 27 a-27 b illustratively each have a square-shaped top surface with bevelled corners. The second posts 28 a-28 c illustratively each have a square-shaped top surface with concave sides (i.e. inward curvature).

Each of the first denest-feature 17 and the second denest-feature 20 illustratively includes an upper wall 30 extending from the major surface 16, and an outward flange 31 being substantially parallel to the major surface 16 of the lid 11 (i.e. the respective major planes of the major surface 16 and the outward flange 31 are parallel within ±15°). Each of the first denest-feature 17 and the second denest-feature 20 illustratively includes a curved surface 32 extending from the upper wall 30 to the outward flange 31. The curved surface 32 is a continuously curving surface.

The upper wall 30 illustratively includes medial face 34 directly abutting the major surface 16 of the lid 11, a first flanking face 33 a extending from the medial face, and a second flanking face 33 b extending from the medial face from an opposite side. The first flanking face 33 a and the second flanking face 33 b extend vertically along opposing sides of the curved surface 32. As perhaps best seen in FIG. 7C, the upper wall 30, in particular, the medial face 34, is canted at an angle of 6-14 degrees from an axis perpendicular to the major surface 16 of the lid 11.

As perhaps best seen in FIGS. 2 and 7A, each of the plurality of lower egg receptacles 19 a-191 illustratively includes a first pair of opposing curved protrusions 35 a-35 b (protrusions or recesses, depending on vantage), and a second pair of opposing curved protrusions 36 a-36 b. Each of the plurality of lower egg receptacles 19 a-191 illustratively includes a bottom surface between the first pair of opposing curved protrusions 35 a-35 b and the second pair of opposing curved protrusions 36 a-36 b. The bottom surface illustratively includes a dimple 37 for receiving a respective egg. Helpfully, the first pair of opposing curved protrusions 35 a-35 b, the second pair of opposing curved protrusions 36 a-36 b, and the respective dimples 37 provide for secure retention of the respective eggs.

Each of the first pair of opposing curved protrusions 35 a-35 b and the second pair of opposing curved protrusions 36 a-36 b illustratively includes an upper wall 52, a curved surface 53, and a thin strip surface 54 extending around a perimeter of the curved surface and adjacent sides of the upper wall. Each of the first pair of opposing curved protrusions 35 a-35 b and the second pair of opposing curved protrusions 36 a-36 b illustratively includes an outward flange 55 extending from the curved surface 53 and being substantially parallel to a major surface of the base 21 (i.e. the respective major planes of the base 21 and the outward flange 55 are parallel within ±15°)

As perhaps best seen in FIGS. 1-2, the egg carton 10 illustratively includes a closing clasp 38 coupled to the base 21. The closing clasp 38 illustratively includes a plurality of locking tabs 41 a-41 b. Also, the first opposing longitudinal side 12 of the lid 11 defines first and second locking openings 43 a-43 b, which interface snap fit over the plurality of locking tabs 41 a-41 b when the egg carton 10 is in the closed position. The closing clasp 38 illustratively includes a plurality of semi-circle shaped curved surfaces 42 a-42 b spaced apart therein. In the illustrated embodiment, the first and second locking openings 43 a-43 b are rectangle-shaped, but in other embodiments, the first and second locking openings may have other shapes, and the plurality of locking tabs 41 a-41 b may be formed to respectively fit those other shapes.

As perhaps best seen in FIGS. 2 & 7A, the lid 11 illustratively includes a first inner denest corner 40 and a second inner denest corner 44, which are respectively opposite the first denest-feature 17 and the second denest-feature 20. The second inner denest corner 44 illustratively includes an upper wall 51 having a medial face 47, a first flanking face 48 a extending from the medial face, and a second flanking face 48 b extending from the medial face at an opposite side. The second inner denest corner 44 illustratively includes an outward flange 50 being substantially parallel to the major surface 16 of the lid 11 (i.e. the respective major planes of the major surface 16 and the outward flange 50 are parallel within ±15°), a lug 45 extending from the outward flange, and a curved surface 46 extending between the upper wall 51 and the lug.

The egg carton 10 may comprise any shelf stable material with sufficient rigidity to protect the eggs therein. For example, the egg carton 10 may comprise one or more of foamed plastics, such as polystyrene foam, clear plastic, recycled paper, and molded pulp paper. Moreover, the corners at the first and second longitudinal opposing sides and the first and second opposing ends of the lid 11 and base 21 are illustratively radiused, but in other embodiments, the corners may be bevelled, chamfered, or end in a fine edge.

Advantageously, each of the first denest-feature 17 and the second denest-feature 20 is lugless. This permits the egg carton 10 to consume less space when stored in nested arrangement. Indeed, as shown in FIGS. 8A-8B, the egg carton 10 permits a 50% reduction in denest interval over the prior art egg carton 100 a-100 d. In other words, the egg carton 10 can be stored more efficiently than typical prior art approaches. This greater density is partially due to the curved surface 32 of each of the first denest-feature 17 and the second denest-feature 20. In particular, the curved surface 32 provides for a continuously decreasing surface angle, i.e. a tighter fit between adjacent egg cartons.

Moreover, the reduced height of the second posts 28 a-28 c improves effectiveness of automatic denesting devices. This is due to the reduction of material touching between nested egg cartons 10, i.e. reducing snagging issues. Similarly, the lugless design of each of the first denest-feature 17 and the second denest-feature 20 also improves effectiveness of denesting devices (i.e. removing the typical catch point).

Another aspect is directed to a method of making an egg carton 10 comprising forming a lid 11. The lid illustratively includes a first opposing longitudinal side 12, a second opposing longitudinal side 13, a first opposing end 14, and a second opposing end 15. The first opposing end 14 and the second opposing end 15 are between the first opposing longitudinal side 12 and the second opposing longitudinal side 13. The lid 11 illustratively includes a major surface 16 extending between the first opposing longitudinal side 12 and the second opposing longitudinal side 13 and between the first opposing end 14 and the second opposing end 15. The lid 11 illustratively includes a first denest-feature 17 and a second denest-feature 20 respectively adjacent the first opposing end 14 and the second opposing end 15. Each denest-feature 17, 20 has an upper wall 30 extending from the major surface 16, an outward flange 31 being substantially parallel to the major surface, and a curved surface 32 extending from the upper wall to the outward flange. The method includes forming a base 21. The base 21 includes a first opposing longitudinal side 22, a second opposing longitudinal side 23, a first opposing end 24, and a second opposing end 25. The first opposing end 24 and the second opposing end 25 are between the first opposing longitudinal side 22 and the second opposing longitudinal side 23. The base 21 comprises a plurality of lower egg receptacles 19 a-191 for receiving a corresponding plurality of eggs. The method also comprises forming a hinge strip 26 coupled between the lid 11 and the base 21 and configured to permit the lid to fold between a closed position and an open position.

Yet another aspect is directed to a method of packaging a plurality of eggs in an egg carton 10. The method includes positioning the plurality of eggs in the egg carton 10. The egg carton includes a lid 11 comprising a first opposing longitudinal side 12, a second opposing longitudinal side 13, a first opposing end 14, and a second opposing end 15. The first opposing end 14 and the second opposing end 15 are between the first opposing longitudinal side 12 and the second opposing longitudinal side 13. The lid 11 illustratively includes a major surface 16 extending between the first opposing longitudinal side 12 and the second opposing longitudinal side 13 and between the first opposing end 14 and the second opposing end 15. The lid 11 illustratively includes a first denest-feature 17 and a second denest-feature 20 respectively adjacent the first opposing end 14 and the second opposing end 15. Each denest-feature 17, 20 has an upper wall 30 extending from the major surface 16, an outward flange 31 being substantially parallel to the major surface, and a curved surface 32 extending from the upper wall to the outward flange. The method includes forming a base 21. The base 21 includes a first opposing longitudinal side 22, a second opposing longitudinal side 23, a first opposing end 24, and a second opposing end 25. The first opposing end 24 and the second opposing end 25 are between the first opposing longitudinal side 22 and the second opposing longitudinal side 23. The base 21 comprises a plurality of lower egg receptacles 19 a-191 for receiving a corresponding plurality of eggs. The method also comprises forming a hinge strip 26 coupled between the lid 11 and the base 21 and configured to permit the lid to fold between a closed position and an open position.

Many modifications and other embodiments of the present disclosure will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the present disclosure is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. 

That which is claimed is:
 1. An egg carton comprising: a lid comprising first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, a major surface extending between said first and second opposing longitudinal sides and said first and second opposing ends, and first and second denest-features respectively adjacent said first and second opposing ends, each denest-feature comprising an upper wall extending from said major surface, an outward flange being substantially parallel to said major surface, and a curved surface extending from said upper wall to said outward flange; a base comprising first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and a hinge strip coupled between said lid and said base and configured to permit said lid to fold between a closed position and an open position.
 2. The egg carton of claim 1 wherein said base comprises a plurality of posts between said plurality of lower egg receptacles.
 3. The egg carton of claim 2 wherein said plurality of posts comprises first posts and second posts, said second posts having a height less than that of said first posts.
 4. The egg carton of claim 3 wherein adjacent first posts include a respective second post therebetween.
 5. The egg carton of claim 1 wherein said major surface of said lid is flat.
 6. The egg carton of claim 1 wherein said upper wall extends vertically along opposing sides of said curved surface.
 7. The egg carton of claim 1 wherein said upper wall is canted at an angle of 6-10 degrees from an axis perpendicular to said major surface of said lid.
 8. The egg carton of claim 1 wherein each denest-feature is lugless.
 9. The egg carton of claim 1 wherein each lower egg receptacle comprises first and second pairs of opposing curved protrusions.
 10. The egg carton of claim 9 wherein each lower egg receptacle comprises a bottom surface between said first and second pairs of opposing curved protrusions and comprising a dimple for receiving a respective egg.
 11. An egg carton comprising: a lid comprising first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, a flat major surface extending between said first and second opposing longitudinal sides and said first and second opposing ends, and first and second denest-features respectively adjacent said first and second opposing ends, each denest-feature comprising an upper wall extending from said flat major surface, an outward flange being substantially parallel to said flat major surface, and a curved surface extending from said upper wall to said outward flange, said upper wall extending vertically along opposing sides of said curved surface; a base comprising first and second opposing longitudinal sides, first and second opposing ends between said first and second opposing longitudinal sides, a plurality of lower egg receptacles for receiving a corresponding plurality of eggs, and a plurality of posts between said plurality of lower egg receptacles; and a hinge strip coupled between said lid and said base and configured to permit said lid to fold between a closed position and an open position.
 12. The egg carton of claim 11 wherein said plurality of posts comprises first posts and second posts, said second posts having a height less than that of said first posts.
 13. The egg carton of claim 12 wherein adjacent first posts include a respective second post therebetween.
 14. The egg carton of claim 11 wherein said upper wall is canted at an angle of 6-10 degrees from an axis perpendicular to said flat major surface of said lid.
 15. The egg carton of claim 11 wherein each denest-feature is lugless.
 16. The egg carton of claim 11 wherein each lower egg receptacle comprises first and second pairs of opposing curved protrusions; and wherein each lower egg receptacle comprises a bottom surface between said first and second pairs of opposing curved protrusions and comprising a dimple for receiving a respective egg.
 17. A method of making an egg carton comprising: forming a lid comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and first and second denest-features respectively adjacent the first and second opposing ends, each denest-feature comprising an upper wall extending from the major surface, an outward flange being substantially parallel to the major surface, and a curved surface extending from the upper wall to the outward flange; forming a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and forming a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.
 18. The method of claim 17 wherein the base comprises a plurality of posts between the plurality of lower egg receptacles.
 19. The method of claim 18 wherein the plurality of posts comprises first posts and second posts, the second posts having a height less than that of the first posts.
 20. The method of claim 19 wherein adjacent first posts include a respective second post therebetween.
 21. A method of packaging a plurality of eggs in an egg carton, the method comprising: positioning the plurality of eggs in the egg carton, the egg carton comprising a lid comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, a major surface extending between the first and second opposing longitudinal sides and the first and second opposing ends, and first and second denest-features respectively adjacent the first and second opposing ends, each denest-feature comprising an upper wall extending from the major surface,  an outward flange being substantially parallel to the major surface, and a curved surface extending from the upper wall to the outward flange; a base comprising first and second opposing longitudinal sides, first and second opposing ends between the first and second opposing longitudinal sides, and a plurality of lower egg receptacles for receiving a corresponding plurality of eggs; and a hinge strip coupled between the lid and the base and configured to permit the lid to fold between a closed position and an open position.
 22. The method of claim 21 wherein the base comprises a plurality of posts between the plurality of lower egg receptacles.
 23. The method of claim 22 wherein the plurality of posts comprises first posts and second posts, the second posts having a height less than that of the first posts.
 24. The method of claim 23 wherein adjacent first posts include a respective second post therebetween. 